Needle punch machine



Dec. 3, 1963 A. M. SMITH u 3,112,548

NEEDLE PUNCH MACHINE Original Filed May 26, 1960 4 Sheets-Sheet l Dec. 3, 1963 A. M. SMITH ll NEEDLE PUNCH MACHINE original Filed May 2e, 1960 4 Sheets-Sheet 2 mvEN'roR HMA/@N056 MSW/Afl wen/@ys Dec. 3, 1963 A. M. SMITH u NEEDLE PUNCH MACHINE 4 Sheets-Sheet 3 Original Filed May 26, 1960 IIOO Dec. 3, 1963 A. M. sMl'rH n 3,112,548

NEEDLE PUNCH MACHINE Original Filed May 26, 1960 4 Sheets-Sheet 4 7716-. /2 F76-, /3 'Vo. /4

IN VENTOR. Ha/@waffe f5/'14mg l United States Patent O M 3,7112548 NEEDLE PUNCH MACIHNE Alexander M. Smith Il, Elkin, N C., assigner to Chatham Manufacturing Company, Elkin, N.C., a corporation of North Carolina Original application May 26, 1960, Ser. No. 31,910, now Patent No. 3,090,160, dated May 21, 1963. Divided and this application Sept. 26, 1961, Ser. No. 146,675

6 Claims. (Cl. 28-4) The present invention relates to an improved needle punch machine for making a new and improved needled or non-woven fabric from an improved method of needling. More particularly, the present invention contemplates an improved making a needle punch machine lfor making a needled or non-woven fabric material by providing subsurface interlooping of the fibers and/or some interlacing of the fibers, the invention also contemplating the use of an improved needle punch machine which provides needling of the web from opposite surfaces by utilizing needles adapted to penetrate the web at an acute angle to the direction of web travel.y

This application is a division of my copending application Serial No. 31,910, now U.S. Patent No. 3,090,100, filed May 26, 1960, and is entitled to the filing date thereof.

Non-woven fabric structures, such as felt or felt-like products, derive their coherence and strength from interfiber entanglement and accompanying frictional forces. Heretofore, felts have been produced from wool and wool-like fibers by various mechanical working processes involving rufiing, squeezing, rolling under appropriate conditions of humidity and temperature. The advent of synthetic fibers in recent years has resulted in increased use of a needle punching process as such synthetic fibers do not have a structure which promotes felting by the aforesaid externally applied mechanical processes.

The present invention contemplates utilizing an apparatus for needle punching a web or batt of loosely matted fibers to produce a non-woven fabric having a more positiveinteriiber or chain entanglement, the resulting new and improved needled or non-woven fabric produced having both surfaces uniform in appearance and structure. Further, the resulting new and improved needled or nonwoven fabric of the present invention may be napped .evenly on both sides and yet have better tensile and separation strength after napping than non-woven fabrics heretofore produced. Because of softness with strength, then new and improved needled or non-woven fabric produced by the present invention is especially adapted for use in making blankets of substantial thickness as well as outerwear fabrics or the like. The utility of the method and machine of the present invention is further increased as the new and improved needled or non-woven fabrics may be made from either natural or synthetic fibers, or a blend of natural and synthetic fibers. Two or more webs of loosely matted fibers having a scrim of woven, non-woven or bonded fabric interposed between may be needle punched by the method and machine of the present invention, the resulting needled or non-woven fabric having the desired tensile and separation strength as well as uniform appearance and structure on its surfaces.

Throughout the specification wherever the term interlooping is used, it defines a subsurface binding together of fibers in a web or the like of loosely matted fibers, the binding being accomplished by passing fibers through the loops of other fibers previously oriented below the surface of the web. Interlooping of fibers is akin to knitting as it provides entanglement of fibers by loop engagement rather than a binding by a tying action. On the other hand, the term interlacing as used throughout 3,112,548 Patented Dec. 3, 1963 lCC the specification is intended to define a binding together of fibers primarily from one outside surface of a web to the other outside surface of a web. Interlacng of fibers is somewhat similar to a sewing action although lit does not depend on a continuous threaded action. In interlacing, the ends of fibers lying on one surface are carried through the web body and then returned to the initial side by another path so as to become oriented in a manner analogous to a thread in sewing as distinguished from interlooping where the binding is confined to subsurface fibers.

An important object of the present invention is to provide a new and improved needled or non-woven fabric structure by an improved needle punch machine for needling or punching a web or batt of loosely matted fibers which will result in producing a fabric structure obtaining its coherence and strength primarily from a substantially uniform interlooping of fibers, the resulting, product fabric structure having more tensile and separation strength, density and yet a softness of outer surfaces which makes it highly desirable for use in blankets, outerwear fabrics or other similar products.

Ancillary to the preceding object, it is a further object of the present invention to provide an improved type of needle punching apparatus for accomplishing interlooping and/or interlacing of fibers of a loosely matted fiber web or batt.

A further object of the present invention is to provide an improved apparatus which will compress a web and tightly interloop and/or interlace loosely matted fibers upon one pass through the apparatus, the resulting producthaving extremely high tensile and separation strength.

Still another object of the present invention is to provide an improved needle punch machine for needling loosely matted fibers to produce a needled or non-woven fabric obtaining its strength from interlooping of fibers, the machine needling the web from both sides to obtain a uniform finish on both sides of the resulting product. This is an important consideration when the product is subjected to subsequent finishing operations, particularly napping.

Ancillary to the preceding object, it is a further object of the present invention -to provide an apparatus for interlooping fibers in a loosely matted ber web or batt, the apparatus permitting fewer punches per lineal inch with a more definite interlooping pattern.

A further object of the present invention is to provide an apparatus for needling loosely matted fibers in a web, the apparatus providing less drag upon the web so that a needled or non-woven fabric can be produced faster and with greater strength and more uniform characteristics.

These and other objects and advantages of the present invention |will appear more fully in the following detailed specification, claims and drawings in fwhich:

FIG-URE l is a side elevational v-iew of an improved apparatus for accomplishing the improved novel method of producing the new and improved needled or nonwoven' fabric material of the pnesent invention;

'FIGURE 2 is an enxd elevation looking from the. right of iFlGURE l, parts being omitted for the purpose of clarity;

FIGURE 3 is an enlarged vertical sectional view, partly in elevation, and taken on the line 3 3` of FIGURE 2;

FIGURE 4 is an enlarged fragmentary view of a web guide plate taken on the line 4-4 of FIGUR-E 3;

FIGURE 5 is a view taken on the line 5-'5 of FIG- URE 4;

FIGURES 6 `and 7 illustrative progressive steps of interlooping fibers in cha-in entanglement as the web of Iriateiial passes through the apparatus from the left to the right, the figures showing an opposed pair of cooperating upper and lower needles;

'FIGURE 8 is a schematic view showing the paths of the pair of cooperating needles in FIGURES 6 and 7 superposed upon one another;

[FIGURES 9 through l1 schematically show the penetration pattern lof a pair of opposed needles through a web moving from the left to the right in intermittent step-bystep increments;

FIGURES 12, 13 and 14 schematically show the interlooping of iibers in chain entanglement provided by the i movement of the needles shown in FIGURES 9 to 11, respectively.

Referring now to the drawings wherein` like character and reference numerals represent like or similar parts, and in particular to lFIGURE l, a web or batt of loosely matted fibers generally designated at ,101 is illustrated moving from the left to the right of the ligure through a needle punch machine generally designated at |12. Passing from the machine `i2 at the right hand side of the ligure is a needled or non-woven fabric material shown -in broken lines and generally designated by the numeral 14. -It will be understood that the web or batt of fibrous material may be continuously fed from a conventional carding machine where the ibers are carded and loosely formed into the web or it may be supplied from rolls of such material after the material has been taken from such carding machine and formed into a roll. If desirable, and depending upon the type of end product to be made, the web in FIGURE 1 may be formed from two or more layers of loosely matted fibers such as 16 and [1S (FIG- U'RE 6), the layers being separated by a scrim which is usually loosely woven fabric 20.

After the needled or non-woven fabric structure -14 is produced by the apparatus 112, it will be understood that subsequent treatment of the fabric may occur. dn in- Y stances where the fabric 14 is to be used for blankets or the like, each of the sinfaces of the fabric can be napped by conventional Inapping processes. By the unique interlooping of fibers accomplished by the present method and apparatus, the produced fabric y14 has a high pull apart or separation strength and it retains a majority of this separation strength even after napping.

While the present invention primarily results in interlooping iibers, it also results in some interlacing of fibers. By suitable changes in the method and adjustments in the operation of the machine, more or less interlacing of fibers can be obtained. A more detailed discussion of interlacing appears in my copending application entitled Needle Punch Machine and Method, serially numbered 29,115 and tiled May 13, 1960; now ULS. Patent No. 3,090,099, and it -will be understood that such disclosure is incorporated by reference in this application.

kIn order to accomplish the novel method by the apparatus of the present invention resulting primarily in interlooping of fibers in the web 110 as Well as some interlacing of fibers, the web is advanced through the machine in intermittent step-by-step mot-ion between opposed patterns of needles 22 and 24. The needle patterns 22 and 24 are each arranged to-move on a path of penetra-tion at an acute angle -to and in a direction opposite to the direction of travel of the web 10. While the needle patterns 22 and 24 swing in an arc as will be explained in more detail later in the specification, the radius of the arc is sufficiently great that the needles for all practical purposes travel substantially in -a straight line when penetrating into or withdrawing from the web. In the preferred form of the invention, the center rows of needles of each pattern are made tangent to their arc when the needles are in a position of complete penetration Within the web 10. When arranged in this manner, the needles travel in a path at an acute angle to the web travel and their path of travel is substantially parallel to the longitudinal axes of the needle shafts. An alternative arrangement is to position the center row of needles of the patterns 22 and 24 at a slight yangle to the tangent of their arc when the needles are in a position of complete penetration in the web 10u `'When arranged in this latter manner, the path of travel of the needles is at an acute angle to web travel but such a path is also at a slight angle to the longitudinal axes of the needles.

While the needle patterns 22 and 24 are shown penetrating at an acute angle to and in a direction opposite to the direction of web travel for purposes of description, it will be understood that the path of Itravel of the needles could lbe at van ecute angle to and in the same direction `as the direction of web travel.

Needle patterns l2.2 and 24 include needle 'boards 26 and 28 respectively. An array of needles 30 is carried by the needle board 26 Whereas another array of needles 32 which oppose the needles 30 is carried by the needle board 28. Need-les 30 are arranged on needle board 26 in a pattern which is a mirror image of the pattern of needles 32 arranged on the needle board 28. lAs heretofore mentioned, the needles 30 and 32 enter the web at an acute angle to the direction of feed of the web and since the two needle patterns 22 and 24 are mirror images of one another and operate in cooperation with one another, the paths of a pair of needles 30 and 32 will cross in a median plane of the web '10. A schematic representation of the paths of needles 30 and 32 is shown in FIGURE 8 and while the paths are shown .as crossing, it will be understood that the paths are superposed one upon the other as an opposed pair of needles never enter the web simultaneously and further the web moves between successive penetrations of opposed needles.

A confined throat 34 defined by a pair of spaced apart web'gu-ide plates 35 and 38 provide a path for the web 10 to travel as the needle patterns 22 and 24 alternately punch or needle opposite surfaces of the web, 'the web 10 being moved a small increment between successive penetrations of the patterns. Guide plates 36 and 38 are provided with curved inlet portions 40` and 42 which define a gradually decreasing infeed portion 44 for the throat 34. The infeed portion 44 guides fthe web '10 as it is compressed to a desired ,thickness as defined by the distance between the two guide plates 36 and 38.

Each of the guide plates 36 and 38 is provided with a plurality of holes 46, the holes 46 being arranged to receive the needles 30 and 32 of patterns 22 and 24 respectively. As shown in FIGURES 6 and 7, the needles which enter the web at an angle thereto pass through a pair of holes or slots 46 in the plates 36 and 38 respectively. The holes or slots 46 are elongated in the direction of travel of the web. The array of needles 30 and 32 are substantially identica-l in construction and include barbs 4S arranged yalong the surfaces of the same, the barbs being adapted to engage and orient fibers of the web l10 as the needles are moving on their penetrating stroke, but not engaging the fibers on the withdrawal stroke.

Referring now to FIGURES 6 through 8 inclusive as well as to the schematic FIGURES 9 through 14 inclusive, the letter T represents the direction of travel of the web 10 through the confined throat 34. As mentioned above, the motion of Ithe web through the throat is in step-by-step increments with penetration of the web by the patterns of needles 22 and 24 occurring when the web is stationary. In FIGURE 6, the needle 30 of the upper pat-tern of needles 22 is shown penetrating the web and carrying with it subsurface -fibers as well as some surface fibers of the same. FIGURE 6 illustrates the crienting of bers from the upper surface of the web to a posit-ion wherein some of the looped ends of,

FIGURE l2. schermati-- ing with it some surface fibers and some subsurface fibers of the lower surface of the web.- rIt will be understood that prior to the penetration by the needle 32, needle 30 will have been completely withdrawn from the web and the web will have been moved in the direction of the arrow T a small increment.

'When the needle 32 enters the web as shown in FIG- URE 7, its point of penetration is such that fibers picked up on the surface of the web as well as subsurface fibers are carried through the loops of fibers previously oriented by the needle 30. This is shown schematically in FIGURE 13 wherein the fibers are passing upwardly to the Ileft of the ligure, through the subsurface loops of the fibers previously oriented by the needle 30. Also as shown in FIGURE 13, loops of lthe fibers oriented by the needle 32 are positioned immediately beneath the surface of the web opposite the surface of penetration by the needle 3K2. After needle 32 is withdrawn from the web, the web is again advanced a small increment. Needle '30 begins its penetration after the web has stopped and as shown in FIGURE 14, rfibers being oriented by the needle 3l) are threaded through loops of fibers previously oriented by the needle 32. The alternate penetration of the oppositely disposed needles 30 and 32 continues as the web is moved in stepJby-step motion through the confined throat 34.

FIGURE 8 illustrates the paths of penetration of opposed mirror image needles `30 and 32 superposed upon one another. Each pair of opposed needles 30 and 32 is arranged to penetrate through the web and intersect in a median plane represented by the broken line M of the web 10. IIt will be understood that the web 10 moves a small increment between successive penetrations of a pair of opposed needles 30 and 32, the increment being suc-h that the initial penetration of the needles will be forward of the position where the opposed needle extended out of the web so that loops previously oriented by the other needle may be threaded. A schematic illustration of the movement of the needles through the median plane M relative to the movement ofthe web is shown in -FIG- URES 9 Vto 111, inclusive. In FIGURE 9, the stationary web is penetrated by the needle 3%, the needle passing through the median plane of the web at a point designated A. As shown in FIGURE 10, the needle 3l?t has been withdrawn from the web, the web has been advanced a small increment and then the needle 32 has penetrated the web. In the position shown, the needle 32 intersects the median plane M of the web at B and the distance between A and B represents the increment of advancement. lFIG- URE 11 `is a further sequential operation showing the needle 32 having been withdrawn, the web advanced and then the needle 30 again penetrating the web and intersecting the median plane at C. FIGURES l2, 13 and 14 show the sequence of inter-looping of fibers to cause a chain entanglement of fibers in a row as represented by the movement of needles as shown in FIGURES 9 to 1l, respectively.

While IFIGURES 12 to 14 do not show surface fibers passing completely through the web, it will be understood that some fibers will be carried through the web as disclosed in my aforementioned application and there will be some interlacing of fibers so as to have a surface-tosurface binding of the web yas well as a subsurface-tosubsurface binding of the web by interlooping.

Referring now to FIGURE 4, the needle pattern 22 of needles 30 is illustrated, it being understood that the pattern 24 of needles 32 is an identical mirror image of the pattern 22. Needles 30 are arranged in a plurality of rows extending transverse of the direction of travel of web 110. The rows of needles are staggered so that more needles may be punching the web transversely of the same in each widthwise inch. In other words, because the size of the needles will not permit the needles to be placed in close enough spaced relationship widthwise of the web, the rows of needles are staggered so as to provide a high number of needles punching the web for each widthwise inch 4of the web.

To accomplish effective interlooping by the above described method, it has been found that each needle pattern 22 and 24 must have an array of needles which will provide a range of needle punches per widthwise linch of the web 10 of about 25 punches to about 75 punches. Thus, in effect, there will be 25 to 75 paths of punches per widthwise inch as the web is advancing between the needle patterns 22 and 24. With the above range of widthwise punches, it has been found that each needle of each pair of opposed needles should penetrate the web 10- in a range of 6 to 20 penetrations per linear -inch of ble web to obtain effective interlooping of fibers. On the other hand, effective interlacing has well as interlooping of fibers can be obtained within a range of 4 to 20 penetrations per linear inch. A preferable range of punches per linear cinch is 7 to 14 penetrations for each needle of each pair of needles. The number of penetrations per linear inch is accomplished by moving the web in stepby-step increments for each successive penetration of a needle pattern, the increment of movement being determined by the range desired.

Barbed penetration, which is the distance of penetration through the web of the barb closest to the point of the needle, has been accomplished in a range of from the surface of the web opposite the surface of penetration to a point where the aforesaid barb extends one-half of an i-nch from the surface. A range of barbed penetrations for maximum interlooping plus some interlacing is obftained in a range from the surface of the web opposite the surface of penetration to a point one-eighth of an inch beyond the surface opposite the surface of penetration Whereas a range of barbed penetrations for maxii mum interlacing and good interlooping has been found to be one-eighth .of an inch through the web beyond the surface opposite the surface of penetration and no lgreater than one-half of an inch through the web beyond the surface opposite the surface of penetration.

As mentioned above, the path of penetration of the needles is at an acute angle to the direction of travel oli the web 10. The preferable range in angularity of rthe path of penetration with respect to a normal through the web -has been found to be about 8 to about 12. This range of angularity is effective both when the longitudinal axis of the shaft of fthe needle is parallel to the path of penetration and when the axis of the shaft of the needle is at a slight angle to the path of penetration.

As is now apparent, the arrangement of needles traveling at an acute angle to the path of the web provide a needled or non-woven fabric having good tensile and separation strength as well as good compactness and density. Because the needled or non-wolven fabric produced by the aforesaid method results in interlooping and as well as some interlacing, the fabric may be subjected to subsequent operations on both sides such as napping with uniform results. The interlooping of bers causing a subsurface-to-subsurface binding permits the non-woven fabric to be napped without materially reducing its tensile strength of its Vseparation strength. It has been found that by utilizing the aforesaid method, a needled or nonwoven fabric capable of use in making blankets, outerwear fabrics and the like can be'made by punching the fabric at least 6010 punches per square inch upon one' pass through the opposed patterns 4of needles.

The amount of interlooping and interlacing of fibers of a needled or non-woven fabric made according to the foregoing method is a function of the thickness of the finished fabric, the number of punches per linear inch, the angle of the path of penetration, as well as the amount of barbed penetration. However, it will be understood that the aforementioned variable are interdependent if interlooping is to be achieved. Generally, more interlooping of fibers occurs when the needled or non-woven fabric produced is one-eighth inch or greater in thickness. Likewise, the more punches per linear inch produces more linterlooping whereas the lower end of the range produces more interlacing. Further, more interlooping of fibers occurs at the lower end of the barb penetration range whereas interlacing increases with increased barbed penetration.

Referring back to FIGURES 1, 2 and 3, the improved needle punching apparatus 12 for accomplishing the above described method is best illustrated. The needle punching apparatus 12 includes a frame structure 48 made from suitable vertical standards 50, side frame members 52 and cross members 54. Mounted on the upper side frame members 52, on each side of the frame structure 48 are a pair of spaced parallel vertically extending plates S6 which are adapted to support therebetween the guide plates 36 and 38. The guide plates 316 and 33 are supported in any suitable manner such as disclosed in detail in my aforementioned application serially numbered 29,115. These plates may be adjusted relative to each other so that the spacing between the plates may be varied to conform to the desired compression of the web 10. Side plates 56 are provided with horizontally extending slots 58 and 60. Aligned slots 58 of side plates 55 are adapted to receive the ends of a shaft 62 which supports one pulley 64 of an endless conveyor structure l66. The

end portion of shaft 6-2 which extends outwardly of the plate 56 as shown in FIGURE 1, is provided with a drive sprocket 6.8.

Slots 60 in plates 56 receive the ends of a shaft 7i) which supports an outfeed roller 72. Carried outwardly of the plates 56 on the end of the shaft 70 is a drive sprocket 74 (FIGURE 1). A one-way clutch and brake assembly (not shown) is coupled to the other end of shaft 70 in a manner such as disclosed in my aforementioned application serially numbered 29,115. A drive chain 76 trained around the sprockets 68, 74 and an idler sprocket 78 causes the pulley 64 to be rotated in step-by-step increments when the shaft 70 is rotated in step-by-step increments by the one-way clutch and brake assembly (not shown).

Cooperating with the outfeed roller 72 is a weighted roller S carried on a shaft S2 supported in diametrically opposed slots 84. Weights may be provided on the outer ends of the shaft l32 so that the roller 80 bears against the upper surface of the non-woven fabric 14 as it is discharged from the machine.

A crank arm S6 connected to the drive member of the one-way clutch and brake assembly (not shown) is actuated by a connecting arm 38 pivotally connected thereto and to a disk or wheel S19 (FIGURE 2) keyed to a shaft 9i) rotatably supported in the bearing pillow blocks 92. Shaft 90 also carries a drive wheel 94 which is rotated by a belt 96 coupled to a source of power such as the electric motor 98. As will now be understood, continuous rotation of the shaft 9i) by the motor 98 will cause the crank 86 to oscillate back and forth. Since the crank is connected to the drive member of the one-way clutch and brake assembly, clockwise movement of the crank will cause rotation of the outfeed roller 72 in a clockwise direction as well as rotation of the pulley 64 and movement of the conveyor structure 66 in a direction of web feed. During counterclockwise movement of the crank 86, the roller 72 and the conveyor structure 66 will be stationary and consequently, there will be no feed of the web V through and out of the machine.

As previously stated, the upper needle pattern 22 includes a plurality of downwardly extending needles 3i) carried in the needle board 26. Likewise, the lower needle pattern 24 includes a plurality of upwardly eX- tending needles 32 carried in a lower needle board 2S. Needle board 26 is tixedly m-ounted on the end of elongated rocker arms 100 which are pivotally supported as indicated at ,1012 to a pair of wertical standards 104' xedly secured yon opposite side frame members 52 of the frame structure 48. Lower needle board 23 is tixedly supported as indicated at 106 to the ends of elongated rocker arms 198 also pivotally supported as indicated at 110 to the vertical standards 104.

Connecting rods 112 on opposite sides of the needle boards, pivotally connect the upper needle board 26 to the lower needle board 2S as indicated at 114. Thus, when the lower needle board is moved vertically upwardly and downwardly the upper needle board 26 is simultaneously moved upwardly and downwardly.

Extending vertically downwardly beneath the lower needie board 23 and fixedly connected thereto is a pair of brackets 116 to which the forward ends of the rocker arms 108 are connected. The brackets 116 are pivotally connected as indicated at y118 to a pair of crank arms 12.0 coupled to cranks 122 carried on a shaft 124 supported in bearing pillow blocks 126. The shaft 124, .which rotates the cranks 122, is provided with a drive sprocket 128 driven by a chain 130* trained about a sprocket 132 keyed to the drive shaft 90.

As is now apparent from the foregoing description and the drawings, the feed of the web 10 in step-by-step increments is timed to the movement of the needle patterns 22 `and 24. Drive shaft is rotated by motor 98 and its rotation causes continuous up and down movement of the patterns 22 and 24A about their pivotal axes 102 and 110, respectively. Timed to the up and down movement of the patterns 22 and 24 is the step-by-step feeding of the web 10 bet-Ween the patterns. This is also accomplished by rotation of the shaft 90* which in turn oscillates the crank arm 86 of the one-Way clutch and brake assembly causing step-by-step feeding of the web in timed relationship to movement of needle patterns 22 and 24. In more detail and assuming the upper pattern of needles 22 is on its down stroke, the web 10 will be stationary as the crank arm.86 is moving in counterclockwise direction. After the array of needles 30 of pattern l22 have penetrated the web orienting the fibers as hereto described, the array of needles 3U will begin to withdraw from the web. When the needles 30 are completely out of the web and prior to the array of needles 32 of pattern 24 entering in the web, the crank arm 86 will rotate in a clockwise direction to yadvance the web the desired increment in its step-by-step movement. Immediately after the web has stopped, the lower pattern of needles 24 will begin their penetration through the web.

' Referring now to FIGURE 3, lit will be noted that the first few rows of needles 30l and 32 of upper and lower needle patterns 22 and 24 respectively pass through the curved inlet portions 40 and 42 of guide plates 36 and 58. Some of these needles do not pass completely through the web as heretofore described but merely enter the web and compress the web in the tapering infeed portion 44 of the throat 34. In other words, the needles in the forward portion of the patterns are not entirely effective to cause interlooping `and/or interlacing of the loosely matted fibers but they do compress the web to proper thickness and density for passage through the confined throat 34. The contour of the plates 36 and 38 is such that they conform to the web as it is compressed, that is, they are spaced apart a distance which allows no up and down napping motion of the web during the needle process.

Throughout the specification, the novel fabric structure or material produced by the novel method and apparatus has been referred to as a needled or non-woven fabric structure. It will be understood that the term needled or the term non-Woven includes any fabric structure made primarily from a -web or batt of loosely-woven fibers with or :without a woven or non-.woven scrim.

efiectively accomplished, it will be understood that the improved method and/or apparatus is subject to Some` changes and modifications without departing from the principles and scope of the invention involved. Therementioned means causing each set of needles to have a path of penetration through the web at an acute angle to a median plane through the web, and said last-mentioned means including means to elect alternate penetration of the web by said opposed sets of needles, said web advancement means being coordinated with said means to elect alternate penetration to cause web movement after each penetration of the lweb by a set of needles.

2. The structure dened in claim 1 Avherein the needles of said sets of needles have paths of penetration into the web which substantially intersect each other in a median plane through the web.

3. In a machine for needl-ing a web of loosely matted iibers for producing la non-woven fabric: a frame structure; a pair of elongated rocker arms pivotally mounted on said frame structure; opposed needle boards carried on the free ends of said rocker arms, each of said needle boards having a set of a plurality of needles; means for advancing the web between said opposed needle boards in step-by-step increments; :and means for moving said needle boards to effect penetration of said web alternately from opposite sides of the same, said Web advancement means being coordinated with said last-mentioned means l@ to cause web movement after each penetration of the web by a set of needles, the penetration and withdrawal of each of said sets of needles being when the web is stationary.

4. The structure dened in claim 3 :wherein said means for moving said needle boards Ato etect Ialternate penetration of ysaid web includes means operatively coupling said needle boards together whereby movement of one needle hoard toward a surface of said web is simultaneously accomplished with movement of the other needle hoard away from the opposite surface of said web.

5. The structure defined in claim 3 wherein said elongated rocker arms have pivotal axes forward of said needle boards in a direction from which said web is advanced whereby said needle sets of said needle Iboards penetrate said web in a path at an Aangle to :and opposite of the direction of advancement of said web.

6. The structure defined in claim 3 including spaced guide plates defining a confined 4throat for said web, Said spaced guide plates having a plurality `of elongated holes therethrough arranged to receive said sets of needles as said sets of needles penetrate and are withdrawn from said web.

References Cited in the le of this patent UNITED STATES PATENTS 

1. IN A MACHINE FOR NEEDLING A WEB OF LOOSELY MATTED FIBERS FOR PRODUCING A NON-WOVEN FABRIC: OPPOSED SETS OF NEEDLES; MEANS FOR ADVANCING THE WEB IN STEP-BY-STEP INCREMENTS THROUGH THE OPPOSED SETS OF NEEDLES; AND MEANS FOR CAUSING SAID SETS OF NEEDLES TO PENETRATE OPPOSITE SURFACES OF THE WEB WHEN THE WEB IS STATIONARY, SAID LASTMENTIONED MEANS CAUSING EACH SET OF NEEDLES TO HAVE A PATH OF PENETRATION THROUGH THE WEB AT AN ACUTE ANGLE TO A MEDIAN PLANE THROUGH THE WEB, AND SAID LAST-MENTIONED MEANS INCLUDING MEANS TO EFFECT ALTERNATE PENETRATION OF THE WEB BY SAID OPPOSED SETS OF NEEDLES, SAID WEB ADVANCEMENT MEANS BEING COORDINATED WITH SAID MEANS TO EFFECT ALTERNATE PENETRATION TO CAUSE WEB MOVEMENT AFTER EACH PENETRATION OF THE WEB BY A SET OF NEEDLES. 